Carton and method for making

ABSTRACT

A carton and a method for making the carton, such as a box for packaging a medicine bottle. A sheet, such as a cardboard sheet, has creases dividing the sheet into panels. A first group of panels are bent along adjacent creases, and two of the panels of the first group are attached together, to create a box. At least one panel not of the first group is located outside the box and defines a creaseably-hinged outsert having two sides each preferably containing printed instructions. The creaseably-hinged outsert is removably and overlyingly attached to one of the panels of the first group, such as by hot-melt-tacking using a semi-pressure sensitive hot-melt adhesive. The user peels up the tacked portions of the creaseably-hinged outsert to read the instructions on both sides.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to packaging, and more particularly to a carton and to a method for making the carton.

[0002] Conventional unassembled cardboard cartons include those having a cardboard sheet having creases which divide the sheet into panels. Conventional carton making machinery includes those machines which bend the panels along adjacent creases, and which glue together two of the panels, to create a box which, at this stage, has an open top and an open bottom. Other machines then fold and insert the bottom panels to close the bottom of the box. A product, such as a medicine bottle, is then inserted by machine into the box through its open top. In a separate step, an insert typically is inserted into the box containing the product. Typically, the folded insert is a printed pamphlet containing instructions, for using the product, which are too lengthy to be printed on the box and which are too lengthy or inconvenient to be printed on the product. Examples of instructions include patient instructions for the person taking the medicine contained in the medicine bottle in the carton.

[0003] Additional machines then fold and insert the top panels to close the top of the box. In one conventional variation, instead of the insert being placed in the box separately from the product, a paper or plastic outsert is folded and removably attached by machine to the product itself before the product is inserted in the box. The paper or plastic outsert contains the printed instructions for using the product. One of the folded panels of the paper or plastic outsert typically is “permanently” attached to the product, and the outsert is folded such that one of the other panels holds the other panels in place by being removably attached, with an adhesive, to the “permanently” attached panel.

[0004] It is known in the magazine industry to use a semi-pressure sensitive hot-melt adhesive to hold in place magazine “pull-outs”. The user removes the “pull-out”, which typically contains writing printed thereon, and any adhesive remaining on the “pull-out” is easily removed from the “pull-out” by the user without damaging the legibility of the writing on the “pull-out”.

[0005] What is needed is a more convenient way of bringing together the product, the instructions for using the product, and the carton which contains the product.

SUMMARY OF THE INVENTION

[0006] A first expression of a preferred embodiment of the invention is for an unassembled carton. The unassembled carton includes a sheet having creases dividing the sheet into panels. A first group of the panels are bendable along adjacent creases, and two of the panels of the first group are attachable together, to create a box. At least one panel not of the first group is locatable outside the box and defines a creaseably-hinged outsert. The outsert is removably and overlyingly attachable to one of the panels of the first group. Preferably, the sheet includes cardboard, the outsert has first and second sides each including writing printed thereon, and the outsert is hot-melt-tackable to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive.

[0007] A second expression of a preferred embodiment of the invention is for an assembled carton. The assembled carton includes a sheet having creases dividing the sheet into a multiplicity of panels. A first group of the panels are bent along adjacent creases, and two of the panels of the first group are attached together, to create a box. At least one panel not of the first group is located outside the box and defines a creaseably-hinged outsert. The outsert is removably and overlyingly attached to one of the panels of the box. Preferably, the sheet includes cardboard, the outsert has first and second sides each including writing printed thereon, and the outsert is hot-melt-tacked to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive.

[0008] A first expression of a preferred method of the invention is for making a carton comprising steps a) through c). Step a) includes obtaining a sheet having creases dividing the sheet into a multiplicity of panels. Step b) includes bending a first group of the panels along adjacent creases, and attaching together two of the panels of the first group, so as to create a box, wherein at least one panel not of the first group is located outside the box and defines a creaseably-hinged outsert. Step c) includes removably and overlyingly attaching the outsert to one of the panels of the first group. Preferably, the sheet includes cardboard, the outsert has first and second sides each including writing printed thereon, and step c) includes hot-melt-tracking the outsert to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive.

[0009] Several benefits and advantages are derived from the invention. The preferred method and the preferred embodiment of the carton of the invention provide a box for packaging a product, wherein the box is made from a sheet of panels so as to leave at least one panel, defining a creaseably-hinged outsert, outside, and removably and overlyingly attached to, the box. This eliminates the additional step of the prior art of inserting an insert, along with the product, in the box or of attaching an outsert to the product before inserting the product into the box. The user peels up the tacked portions of the creaseably-hinged outsert to read the writing on both sides of the outsert.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a schematic, planar view a preferred embodiment of the carton of the invention, wherein the carton is shown in its unassembled state as a single sheet having creases dividing the sheet into panels including a first group of the panels and first and second outsert panels, and wherein the back of the panels is shown in the figure;

[0011]FIG. 2 is a side-elevational view showing a partially assembled box formed from the first group of the panels of FIG. 1 and also showing the two outsert panels of FIG. 1 extending to the left of the back of the box;

[0012]FIG. 3 is a side-elevational view of the partially assembled box of FIG. 2, wherein the second outsert panel has been folded along the adjacent crease to the first outsert panel to overly the first outsert panel thus showing the front surface of the second outsert panel and the sites for the hot-melt adhesive to be deposited thereon;

[0013]FIG. 4 a back elevational view of the partially assembled box of FIG. 3, wherein the first outsert panel has been folded over, and tacked against, the box thus showing the front surface of the first outsert panel; and

[0014]FIG. 5 is a perspective view, including the back and the top, of the fully assembled box of FIG. 4, wherein the box has a closed top.

DETAILED DESCRIPTION

[0015] A preferred embodiment of the invention, shown in various stages of assembly in FIGS. 1-5, is for a carton 20 used for packaging a product (not shown). Such products include, without limitation, medicine bottles sold in drug stores. Typically, the carton 20 has a closed top. However, in some applications, the carton 20 has an open top. Typically, the carton 20 has fully enclosed sides. However, in some applications, a side has a cutout to expose the packaged product. The carton 20 is not limited to having four sides, as can be appreciated by the artisan. The carton 20 is understood, for the purpose of describing the invention, to be a container which holds a product, such container fully or partially enclosing the product.

[0016] A first expression of the preferred embodiment of the invention is for an unassembled carton 20, shown in FIG. 1. The unassembled carton 20 is also shown partially assembled in FIGS. 2-4 and fully assembled in FIG. 5. The unassembled carton 20 comprises (and preferably consists essentially of, and more preferably consists of) a sheet 22 having a plurality of creases 24 dividing the sheet 22 into a multiplicity of panels 1-15, wherein a first group 1-13 of the panels are bendable along adjacent creases 24, and two of the panels 1 and 12 of the first group 1-13 are attachable together, to create a box 26, wherein at least one panel 14 and 15 not of the first group 1-13 is disposable outside the box 26 and defines a creaseably-hinged outsert 28, and wherein the outsert 28 is removably and overlyingly attachable to one of the panels 2 of the first group 1-13. In one variation, not shown, the outsert 28 is narrower than shown in FIG. 1 and is removably and overlyingly attachable to one of the panels of the first group which is the adjacent-crease-one of the panels 12 of the first group 1-13.

[0017] Preferably, the sheet 22 comprises (and more preferably consists essentially of, and most preferably consists of) cardboard. In a preferred construction, the two panels 1 and 12 of the first group 1-13 are glueable together to create the box 26. In one example, without limitation, the glue is a formulated copolymer adhesive such as R 40606P manufactured by Capital Adhesives and Packaging Corporation of Mooresville, Ind. In another preferred construction, the outsert 28 is hot-melt-tackable to the one panel 2 of the first group 1-13 using a semi-pressure-sensitive hot-melt adhesive (also known as a peelable hot-melt adhesive).

[0018] In one example, without limitation, the semi-pressure-sensitive hot-melt adhesive is HM 27 manufactured by Capital Adhesives and Packaging Corporation of Mooresville, Ind. Preferably, the box 26 is a completely enclosed box.

[0019] In one example, the outsert 28 has first and second sides 30 and 32 each including writing printed thereon (summarized as “ABC and “DEF” on the first side 30 and summarized as “GHI” and “JKL” on the second side 32 as shown in the figures). Typically, but not necessarily, the writing includes directions for the user on how to use the packaged product, such as instructions for a patient on how to take the medicine in the packaged medicine bottle. The term “writing” includes, without limitation, letters, numbers, symbols, graphs, and pictures, etc. The term “printed” includes any method for affixing the writing to the sides of the outsert such as, without limitation, ink printing, adhering a thin film or films (containing the writing) onto the sides of the outsert, thermal printing, photo developing, etc.

[0020] In one design, the at-least one panel 14 and 15 defining the outsert 28 comprises first and second outsert panels 14 and 15, wherein the first outsert panel 14 is attached to the box 26 by an adjacent one of the creases 24, and wherein the second outsert panel 15 is attached to the first outsert panel 14 by an adjacent one of the creases 24. Preferably, the second outsert panel 15 is foldable along the adjacent crease 24 to the first outsert panel 14, is disposable between the one panel 2 of the first group 1-13 and the first outsert panel 14, and is removably and overlyingly attachable to the one panel 2 of the first group 1-13. Two hot-melt adhesive sites 34 of the second outsert panel 15 are shown in FIG. 3. In one variation, not shown, the first and second outsert panels 14 and 15 are narrower than shown in FIG. 1, the second outsert panel 15 is foldable along the adjacent crease 24 to the first outsert panel 14, is disposable between one of the panels of the first group, which is the adjacent-crease-one of the panels 12 of the first group 1-13, and the first outsert panel 14, and is removably and overlyingly attachable to one of the panels of the first group which is the adjacent-crease-one of the panels 12 of the first group 1-13. Preferably, the second outsert panel 15 includes writing printed thereon. In most applications, both sides of each of the first and second outsert panels 14 and 15 include writing printed thereon.

[0021] The outsert 28 is not limited to first and second outsert panels 14 and 15. In some applications, not shown, the outsert consists of a single outsert panel. In other applications, not shown, the outsert includes three, four, or any number of outsert panels attached together along adjacent creases. The outsert panels need not be attached together in a single row, along adjacent creases. Thus, the second outsert panel 15 could be attached, by an adjacent crease, to the top of first outsert panel 14 instead of being attached to the side of the first outsert panel 14. Other arrangements, and folding sequences, of the outsert panels are left to the artisan. For practical applications, the number of outsert panels is limited by the thickness of the outsert panels.

[0022] A second expression of the preferred embodiment of the invention is for an assembled carton 20, shown in FIG. 5. The assembled carton 20 is also shown partially assembled in FIG. 2-4 and unassembled in FIG. 1. The assembled carton 20 comprises (and preferably consists essentially of, and more preferably consists of) a sheet 22 having a plurality of creases 24 dividing the sheet 22 into a multiplicity of panels 1-15, wherein a first group 1-13 of the panels are bent along adjacent creases 24, and two of the panels 1 and 12 of the first group 1-13 are attached together, to create a box 26, wherein at least one panel 14 and 15 not of the first group 1-13 is disposed outside the box 26 and defines a creaseably-hinged outsert 28, and wherein the outsert 28 is removably and overlyingly attached to one of the panels 2 of the box 26. In one variation, not shown, the outsert 28 is narrower than shown in FIG. 1 and is removably and overlyingly attached to one of the panels of the box which is the adjacent-crease-one of the panels 12 of the box 26.

[0023] In a preferred construction, the two panels 1 and 12 of the first group 1-13 are glued together to create the box 26. In another preferred construction, the outsert 28 is hot-melt-tacked to the one panel 2 of the box 26 using a semi-pressure-sensitive hot-melt adhesive (also known as a peelable hot-melt adhesive).

[0024] Preferably, the second outsert panel 15 is folded along the adjacent crease 24 to the first outsert panel 14, is disposed between the one panel 2 of the box 26 and the first outsert panel 14, and is removably and overlyingly attached to the one panel 2 of the box 26. In one variation, not shown, the first and second outsert panels 14 and 15 are narrower than shown in FIG. 1, the second outsert panel 15 is folded along the adjacent crease 24 to the first outsert panel 14, is disposed between one of the panels of the box, which is the adjacent-crease-one of the panels 12 of the box 26, and the first outsert panel 14, and is removably and overlyingly attached to one of the panels of the box which is the adjacent-crease-one of the panels 12 of the box 26.

[0025] A first preferred method of the invention is for making a carton 20 and comprises steps a) through c). Step a) includes obtaining a sheet 22 having a plurality of creases 24 dividing the sheet 22 into a multiplicity of panels 1-15. Step (b) includes bending a first group 1-13 of the panels along adjacent creases 24, and attaching together two of the panels 1 and 12 of the first group, so as to create a box 26, wherein at least one panel 14 and 15 not of the first group is disposed outside the box 26 and defines a creaseably-hinged outsert 28. Step c) includes removably and overlyingly attaching the outsert 28 to one of the panels 2 (or 12 with a narrower outsert than that shown in FIG. 1) of the first group 1-13.

[0026] In one implementation, step b) is performed before step c). In another implementation, step c) is performed before step b). In a further implementation, portions of step b) are performed to partially create the box 26, then step c) is performed, and then the remaining portions of step b) are performed to fully create the box.

[0027] In one application, step b) includes gluing together the two panels 1 and 12 of the first group 1-13. In another application, step c) includes hot-melt-tacking the outsert 28 to the one panel 2 (or 12 with a narrower outsert than that shown in FIG. 1) of the first group 1-13 using a semi-pressure-sensitive hot-melt adhesive. In a further application, the method also includes the steps of folding the second outsert panel 15 along the adjacent crease 24 to the first outsert panel 14, disposing the second outsert panel 15 between the one panel 2 (or 12 with a narrower first and second outsert panels than those shown in FIG. 1) of the first group 1-13 and the first outsert panel 14, and removably and overlyingly attaching the second outsert panel 15 to the one panel 2 (or 12 as previously described) of the first group 1-13.

[0028]FIG. 1 shows the back of the panels 1-15. In one box-creating technique, glue is applied to the front side of panel 1, and panels 1, 2, 6, 10, and 12 are bent along their adjacent creases 24. Then, panel 1 is brought above (referring to FIG. 1) and across the back of panels 2, 6, and 10, and the glue-containing front (not seen in FIG. 1) of panel 1 is attached by pressing to the back (shown in FIG. 1) of panel 12 creating a box with an open top and an open bottom. Then, the bottom side tab panels 5 and 11 are bent inward, the bottom main tab panel 9 is bent inward, and the bottom end tab panel 8 is inserted into the box 20 to close the bottom and create the open-top box 26 shown in FIG. 2. Next, a semi-pressure-sensitive hot-melt adhesive is applied to the hot-melt adhesive sites 34 of the second outsert panel 15, the second outsert panel 15 is folded over the first outsert panel 14 (as seen in FIG. 3), the first outsert panel 14 is bent to overly the one panel 2 (or 12 as previously described) of the first group 1-13, and the first outsert panel 14 is pressed pressing and adhering the second outsert panel 14 to the one panel 2 (or 12 as previously described) of the first group 1-13 as seen in FIG. 4. The product (not shown) is inserted into the box from the open top. Then, the top side tab panels 7 and 13 are bent inward, the top main tap panel 3 is bent inward, and the top end tab panel 4 is inserted into the box 20 to close the top and create the closed-top box 20 seen in FIG. 5. In one variation, the product is inserted into the box through an open bottom, and in another variation, the sides of the box are bent around the product, as is within the level of skill of the artisan. The user peels up the tacked portions of the creaseably-hinged outsert 28 to read the instructions on both sides of the outsert 28. The creaseably-hinged outsert 28 is designed to remain hingeably attached to the box 28 by the adjacent crease 24 with panel 12.

[0029] Several benefits and advantages are derived from the invention. The preferred method and the preferred embodiment of the carton of the invention provide a box for packaging a product, wherein the box is made from a sheet of panels so as to leave at least one panel, defining a creaseably-hinged outsert, outside, and removably and overlyingly attached to, the box. This eliminates the additional step of the prior art of inserting an insert, along with the product, in the box or of attaching an outsert to the product before inserting the product into the box. The user peels up the tacked portions of the creaseably-hinged outsert to read the writing on both sides of the outsert.

[0030] As can be appreciated by the artisan, the outsert 28 is not limited to being creaseably-hinged to a panel of the box 26 used to create a side of the box, but may be creaseably hinged to a panel of the box used to create the top or bottom of the box. For example, in FIG. 1, if an additional panel (not shown) equal in height to panel 9 extended downward from panel 2, the bottom of the box can be created from the additional panel and panels 5, 9, and 11, wherein panel 8 defines the outsert, or the bottom of the box can be created from panels 5, 8, 9, and 11, wherein the additional panel defines the outsert.

[0031] The foregoing description of a preferred method of the invention and of several expressions of a preferred embodiment of the invention has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the invention to the precise forms and processes disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto. 

What is claimed is:
 1. An unassembled carton comprising a sheet having a plurality of creases dividing the sheet into a multiplicity of panels, wherein a first group of the panels are bendable along adjacent creases, and two of the panels of the first group are attachable together, to create a box, wherein at least one panel not of the first group is disposable outside the box and defines a creaseably-hinged outsert, and wherein the outsert is removably and overlyingly attachable to one of the panels of the first group.
 2. The unassembled carton of claim 1, wherein the two panels of the first group are glueable together to create the box.
 3. The unassembled carton of claim 1, wherein the outsert is hot-melt-tackable to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive.
 4. The unassembled carton of claim 1 wherein the sheet comprises cardboard.
 5. The unassembled carton of claim 1, wherein the box is a completely enclosed box.
 6. The unassembled carton of claim 1, wherein the outsert has first and second sides each including writing printed thereon.
 7. The unassembled carton of claim 1, wherein the at-least one panel defining the outsert comprises first and second outsert panels, wherein the first outsert panel is attached to the box by an adjacent one of the creases, and wherein the second outsert panel is attached to the first outsert panel by an adjacent one of the creases.
 8. The unassembled carton of claim 7, wherein the second outsert panel is foldable along the adjacent crease to the first outsert panel, is disposable between the one panel of the first group and the first outsert panel, and is removably and overlyingly attachable to the one panel of the first group.
 9. The unassembled carton of claim 8, wherein the second outsert panel includes writing printed thereon.
 10. The unassembled carton of claim 1, wherein the two panels of the first group are glueable together to create the box, p1 wherein the outsert is hot-melt-tackable to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive, wherein the sheet comprises cardboard, wherein the box is a completely enclosed box, and wherein the outsert has first and second sides each including writing printed thereon.
 11. An assembled carton comprising a sheet having a plurality of creases dividing the sheet into a multiplicity of panels, wherein a first group of the panels are bent along adjacent creases, and two of the panels of the first group are attached together, to create a box, wherein at least one panel not of the first group is disposed outside the box and defines a creaseably-hinged outsert, and wherein the outsert is removably and overlyingly attached to one of the panels of the box.
 12. The assembled carton of claim 11, wherein the two panels of the first group are glued together to create the box.
 13. The assembled carton of claim 11, wherein the outsert is hot-melt-tacked to the one panel of the box using a semi-pressure-sensitive hot-melt adhesive.
 14. The assembled carton of claim 11 wherein the sheet comprises cardboard.
 15. The assembled carton of claim 11, wherein the box is a completely enclosed box.
 16. The assembled carton of claim 11, wherein the outsert has first and second sides each including writing printed thereon.
 17. The assembled carton of claim 11, wherein the at-least one panel defining the outsert comprises first and second outsert panels, wherein the first outsert panel is attached the box by an adjacent one of the creases, and wherein the second outsert panel is attached to the first outsert panel by an adjacent one of the creases.
 18. The assembled carton of claim 17, wherein the second outsert panel is folded along the adjacent crease to the first outsert panel, is disposed between the one panel of the box and the first outsert panel, and is removably and overlyingly attached to the one panel of the box.
 19. The assembled carton of claim 18, wherein the second outsert panel includes writing printed thereon.
 20. The assembled carton of claim 11, wherein the two panels of the first group are glued together to create the box, wherein the outsert is hot-melt-tacked to the one panel of the box using a semi-pressure-sensitive hot-melt adhesive, wherein the sheet comprises cardboard, wherein the box is a completely enclosed box, and wherein the outsert has first and second sides each including writing printed thereon.
 21. A method for making a carton comprising the steps of: a) obtaining a sheet having a plurality of creases dividing the sheet into a multiplicity of panels; b) bending a first group of the panels along adjacent creases, and attaching together two of the panels of the first group, so as to create a box, wherein at least one panel not of the first group is disposed outside the box and defines a creaseably-hinged outsert; and c) removably and overlyingly attaching the outsert to one of the panels of the first group.
 22. The method of claim 21, wherein step b) includes gluing together the two panels of the first group.
 23. The method of claim 21, wherein step c) includes hot-melt-tacking the outsert to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive.
 24. The method of claim 21 wherein the sheet comprises cardboard.
 25. The method of claim 21, wherein the box is a completely enclosed box.
 26. The method of claim 21, wherein the outsert has first and second sides, and also including the step of printing writing on the first and second sides.
 27. The method of claim 21, wherein the at-least one panel defining the outsert comprises first and second outsert panels, wherein the first outsert panel is attached to the box by an adjacent one of the creases, and wherein the second outsert panel is attached to the first outsert panel by an adjacent one of the creases.
 28. The method of claim 27, also including the steps of folding the second outsert panel along the adjacent crease to the first outsert panel, disposing the second outsert panel between the one panel of the first group and the first outsert panel, and removably and overlyingly attaching the second outsert panel to the one panel of the first group.
 29. The method of claim 28, also including the step of printing writing on the second outsert panel.
 30. The method of claim 21, wherein the two panels of the first group are glued together to create the box, wherein the outsert is hot-melt-tacked to the one panel of the first group using a semi-pressure-sensitive hot-melt adhesive, wherein the sheet comprises cardboard, wherein the box is a completely enclosed box, and wherein the outsert has first and second sides each including writing printed thereon. 